A sensor arrangement is for monitoring a circulation pump system (1) which includes at least one pump (3). The sensor arrangement includes a first vibration sensor (5) installed at a first pump part (11) of one of the at least one pump (3) and a second vibration sensor (7) installed at a second pump part (13) of the pump (3) and an evaluation module (9). The first pump part (11) and the second pump part (29) have a distance to each other. The evaluation module (9), is configured to discriminate between at least two of k≥2 different types of faults based on comparing first signals received from the first vibration sensor (5) and second signals received from the second vibration sensor (7).
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27. A method for monitoring an operation of a circulation pump system, the method comprising:
receiving first signals from a first vibration sensor arranged at a first pump part of a pump of the circulation pump system,
receiving second signals from a second vibration sensor arranged at a second pump part of said pump of the circulation pump system, wherein the first pump part and the second pump part have a distance to each other, and
discriminating between at least two of k≥2 different types of faults based on comparing the first signals and the second signals, wherein a time delay between the first signals and the second signals is analyzed to distinguish between inlet-sided external faults and outlet-sided external faults.
1. A sensor arrangement for monitoring a circulation pump system with at least one pump, wherein the sensor arrangement comprises:
a first vibration sensor installed at a first pump part of the at least one pump;
a second vibration sensor installed at a second pump part of said at least one pump, wherein the first pump part and the second pump part have a distance to each other; and
an evaluation module, wherein the evaluation module is configured to discriminate between at least two of k≥2 different types of faults based on comparing first signals received from the first vibration sensor and second signals received from the second vibration sensor, wherein the evaluation module is configured to analyze a time delay between the first signals and the second signals to distinguish between inlet-sided external faults and outlet-sided external faults.
15. A circulation pump system comprising:
at least one pump; and
a sensor arrangement, the sensor arrangement comprising:
a first vibration sensor installed at a first pump part of the at least one pump;
a second vibration sensor installed at a second pump part of said at least one pump, wherein the first pump part and the second pump part are spaced a distance from each other; and
an evaluation module, wherein the evaluation module is configured to discriminate between at least two of k≥2 different types of faults based on comparing first signals received from the first vibration sensor and second signals received from the second vibration sensor, wherein the evaluation module is configured to analyze a time delay between the first signals and the second signals to distinguish between inlet-sided external faults and outlet-sided external faults.
2. The sensor arrangement according to
3. The sensor arrangement according to
4. The sensor arrangement according to
5. The sensor arrangement according to
6. The sensor arrangement according to
7. The sensor arrangement according to
8. The sensor arrangement according to
9. The sensor arrangement according to
10. The sensor arrangement according to
11. The sensor arrangement according to
12. The sensor arrangement according to
13. The sensor arrangement according to
14. The sensor arrangement according to
16. The circulation pump system according to
17. The circulation pump system according to
18. The method according to
19. The method according to
20. The method according to
21. The method according to
discriminating between at least two of k≥2 different types of faults based on the first signals and
validating or rejecting such a discrimination based on the second signals.
22. The method according to
23. The method according to
24. The method according to
25. The method according to
26. The method according to
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This application is a United States National Phase Application of International Application PCT/EP2019/077689, filed Oct. 14, 2019, and claims the benefit of priority under 35 U.S.C. § 119 of European Application 18204237.4, filed Nov. 5, 2018, the entire contents of which are incorporated herein by reference.
The present disclosure is directed to a sensor arrangement and a method for monitoring a circulation pump system.
It is known to use a vibration sensor in a pump assembly for detecting operating faults. For instance, EP 1 972 793 B1 describes a method and pump assembly using a vibration sensor for detecting operating faults, wherein the influence of the rotational speed of the rotating shaft is eliminated for analyzing the vibration signal.
However, in a circulation pump system with one or more pumps, a vibration signal that is interpreted as a pump fault may in fact originate from outside the pump by travelling into the pump via the piping connected to the pump. The fault may in fact be in another pump, a faulty valve or other sources in or connected to the piping.
It is thus desirable to reduce the risk of misinterpreting signals originating from outside of the pump as internal operating faults of the pump.
Embodiments of the present disclosure provide a solution to this problem by providing a sensor arrangement and a method for monitoring a circulation pump system, and a circulation pump system with at least one pump comprising such a sensor arrangement.
In accordance with a first aspect of the present disclosure, a sensor arrangement for monitoring a circulation pump system with at least one pump, wherein the sensor arrangement comprises
For instance, in a simple example, the evaluation module may be configured to discriminate between two types of faults: internal pump fault and fault external to the pump. Comparing between the first signals and the second signals may, for instance, reveal that both sensors detect a very similar vibration, but the second vibration sensor, e.g. being located closer to the pump inlet than the first vibration sensor, detects that vibration earlier than the first vibration sensor, e.g. being installed further away from the pump inlet than the second vibration sensor. In this case, the evaluation module may indicate a fault external to the pump, most likely somewhere upstream in the inlet piping. Vice versa, an internal pump fault may be indicated when the first vibration sensor, e.g. being installed further away from the pump inlet than the second vibration sensor, detects a vibration earlier than the second vibration sensor, e.g. being installed closer to the pump inlet than the first vibration sensor. The first vibration sensor may be installed at a pumphead of the pump. The second vibration sensor may be installed near the pump inlet or pump outlet. In addition, a third vibration sensor may be installed near the other one of the pump outlet and pump inlet, respectively, in order to be able to discriminate between inlet-sided external faults and outlet-sided external faults.
It is important to note that the discrimination between types of faults may not only be based on a comparison of run-time information of the first signals and the second signals. The comparison of the first signals and the second signals as such may increase the confidence in the discrimination between pump faults. Therefore, the sensor arrangement disclosed herein is not only beneficial to reduce the risk of misinterpreting signals originating from outside of the pump as internal operating faults of the pump, but also to reduce the risk of misinterpreting signals as one type of internal fault, whereas in fact another type of internal fault caused the vibration. For instance, the second signals can be used to reject or validate a discrimination between types of faults that was based on the first signals.
The first signals and/or the second signals may be analogue or digital signals generated by the first vibration sensor and/or second vibration sensor upon detecting vibrations of the pump structure and/or of the fluid to be pumped. The first signals and/or the second signals may thus represent the vibrations detected by the first and/or second vibration sensor, respectively. The first signals and/or the second signals may be communicated optically via optical fiber, electrically by wire or wirelessly to the evaluation module. The evaluation module may be implemented in the electronics of the first vibration sensor and/or second vibration sensor or implemented separately from the vibration sensors. It may be implemented as hardware and/or software in the electronics of the pump or a control module external to the pump. Alternatively, or in addition, the evaluation module may be implemented in a remote computer device and/or a cloud-based control system.
The vibration sensors may include a vibration sensing element (e.g. in form of an acceleration sensor element, an optical sensor element, a microphone, a hydrophone, and/or a pressure sensor element). The vibration sensor may detect vibrations of the mechanical structure of the pump and/or vibrations of the pumped fluid in form of pressure waves. The vibrations may be structure-borne and/or fluid-borne sound waves that travel through the pump structure and/or the fluid to be pumped. In the pumped fluid, the vibration waves may be longitudinal, whereas they may be transverse and/or longitudinal in the mechanical structure of the pump. Most preferably, the vibration sensors may be configured to detect longitudinal structure-borne and/or fluid-borne vibration waves. For those longitudinal vibration waves, the propagation speed v may be determined by the Newton-Laplace equation:
wherein K is the bulk modulus and p the density of the medium through which the vibration waves propagate.
Optionally, the different types of faults may comprise at least a subset N of 1≤n≤k types of internal faults originating inside the pump, the subset N comprising at least one type of fault selected from the group consisting of: speed fault, pressure fault, misalignment, bearing fault, drive-end (DE) bearing fault, non-drive-end (NDE) bearing fault, impeller fault, cavitation, dry-running, and water hammer. Any of speed fault, misalignment, bearing fault, drive-end (DE) bearing fault, non-drive-end (NDE) bearing fault, impeller fault, cavitation, and water hammer may have a specific vibration characteristic that may be analysed to distinguish between the different types of faults. Dry-running may be detected by an ultrasonic sensor element integrated in the first and/or second vibration sensor. The first and/or second vibration sensor may thus be a multi-functional sensor having a variety of integrated sensing elements.
Optionally, the different types of faults may comprise at least a subset M of 1≤m≤k types of external faults originating outside the pump, the subset M comprising at least one type of fault selected from the group consisting of: external fault, inlet-sided external fault and outlet-sided external fault.
Optionally, the different types of faults may comprise at least a subset N of 1≤n<k types of internal faults originating inside the pump and a subset M of 1≤m<k types of external faults originating outside the pump.
Optionally, the evaluation module may be configured to discriminate between at least two of k≥2 different types of faults based on the first signals and to validate or reject such a discrimination based on the second signals. These can be types of internal and/or external faults.
Optionally, the first vibration sensor may comprise a vibration sensor element and at least one sensor element selected from the group consisting of: pressure sensor element, accelerometer element, ultrasonic sensor element and optical sensor element.
Optionally, the second vibration sensor may comprise a vibration sensor element and at least one sensor element selected from the group consisting of: pressure sensor element, accelerometer element, ultrasonic sensor element, optical sensor element.
Optionally, the evaluation module may be configured to discriminate between types of faults based on a comparison of run-time information of the first signals and the second signals. For example, a different time-of-arrival of vibration waves at the first and second vibration sensor may indicate whether it is an internal or external fault, respectively.
Optionally, the first vibration sensor may be located at a pumphead of the pump and the second vibration sensor is located at an inlet or outlet of the pump. Optionally, a third vibration sensor may be located at the other one of the inlet and outlet. This may facilitate the discrimination between inlet-sided external faults and outlet-sided external faults.
Optionally, the evaluation module may be configured to compare a first frequency spectrum of the first signals with a second frequency spectrum of the second signals. Before the frequency spectrums are compared by the evaluation module, a filtering, e.g. a Savitzky-Golay filter or locally weighted scatterplot smoothing (LOWESS), may be applied to the first and second signals that are preferably digitally generated by the first and second vibration sensors. The filtering is preferably linear, i.e. the phase response of the filter is preferably a linear function of frequency. A Fast Fourier Transformation (FFT) may be applied to the filtered first and second signals to generate the first and second frequency spectrum, respectively.
Optionally, the evaluation module may be configured to determine a degree of coherence between the first signals and the second signals. Preferably, first and second frequency spectrums of the first and second signals may be used as input into a magnitude squared coherence (MSC) estimate, wherein a Welch's averaged, modified periodogram method may be applied to get a spectral density estimation with reduced noise.
Optionally, the evaluation module may be integrated in the first vibration sensor and/or second vibration sensor.
Optionally, the evaluation module may be external to the first vibration sensor and second vibration sensor.
Optionally, the sensor arrangement may further comprise a communication module for wireless communication with a computer device and/or the evaluation module being external to the first vibration sensor and second vibration sensor. Optionally, the communication module may be integrated in the first vibration sensor and/or second vibration sensor.
In accordance with a second aspect of the present disclosure, a circulation pump system
Optionally, the at least one pump may be a multi-stage centrifugal pump with a stack of impeller stages, wherein a first vibration sensor of the sensor arrangement is installed at a first pump part, e.g. a pumphead of the pump, at a high-pressure side of the stack of impeller stages and a second vibration sensor of the sensor arrangement is installed at a second pump part, e.g. a base member comprising a pump inlet and/or a pump outlet, distanced to the first pump part. The first pump part may be a pumphead.
Optionally, the second vibration sensor of the sensor arrangement may be installed at the pump inlet and a third vibration sensor of the sensor arrangement may be installed at the pump outlet.
In accordance with a third aspect of the present disclosure, a method is provided for monitoring an operation of a circulation pump system comprising:
Optionally, the different types of faults may comprise at least a subset N of 1≤n≤k types of faults originating inside the pump, the subset N comprising at least one type of fault selected from the group consisting of: speed fault, pressure fault, misalignment, bearing fault, drive-end (DE) bearing fault, non-drive-end (NDE) bearing fault, impeller fault, cavitation, dry-running, and water hammer.
Optionally, the different types of faults may comprise at least a subset M of 1≤m≤k types of faults originating outside the pump, the subset M comprising at least one type of fault selected from the group consisting of: outside fault, inlet-sided outside fault and outlet-sided outside fault.
Optionally, the different types of faults may comprise at least a subset N of 1≤n<k types of faults originating inside the pump and a subset M of 1≤m<k types of faults originating outside the pump.
Optionally, the step of discriminating may comprise
Optionally, the step of discriminating may be based on a comparison of run-time information of the first signals and the second signals.
Optionally, the first vibration sensor may be located at a pumphead of the pump and the second vibration sensor is located at an inlet or outlet of the pump.
Optionally, the step of discriminating may comprise comparing a first frequency spectrum of the first signals with a second frequency spectrum of the second signals.
Optionally, the step of discriminating may comprise determining a degree of coherence between the first signals and the second signals.
Optionally, the method may further comprise a step of wirelessly communicating with a computer device and/or an evaluation module being external to the first vibration sensor and second vibration sensor.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
In the drawings:
Referring to the drawings,
The multi-stage centrifugal pump 3 as shown in
The evaluation module 9 receives first signals via the first communication line 15 from the first vibration sensor 5 and second signals via the second communication line 17 from the second vibration sensor 7. The evaluation module 9 is configured to discriminate between at least two of k≥2, where (k∈), different types of faults based on comparing the first signals and the second signals. In a simple embodiment, these two types of faults may be “internal pump fault” and “fault external to the pump”. Comparing between the first signals and the second signals may, for instance, reveal that both vibration sensors 5, 7 detect a very similar vibration, but the second vibration sensor 7 detects that vibration earlier than the first vibration sensor 5. In this case, the evaluation module 9 indicates a fault external to the pump, most likely somewhere upstream in the inlet piping. Vice versa, an internal pump fault may be indicated when the first vibration sensor 5 detects a vibration earlier than the second vibration sensor 7. Based on the discrimination between external and internal faults, the evaluation module 9 may trigger an information broadcast and/or an alarm, e.g. visual, haptic and/or audible, on a stationary or mobile computer device 37 of an operator.
The first vibration sensor 5 and the second vibration sensor 7 are preferably multi-functional sensors including not only a vibration sensing element (e.g. in form of an acceleration sensor element, an optical sensor element, a microphone, a hydrophone, and/or a pressure sensor element) but also other integrated sensing elements. Thereby, receiving the first signals enables the evaluation module 9 to differentiate between a subset N of 1≤n≤k types of internal faults originating inside the pump 3, e.g. speed fault, pressure fault, misalignment, bearing fault, drive-end (DE) bearing fault, non-drive-end (NDE) bearing fault, impeller fault, cavitation, dry-running, and water hammer. A high temperature indicating a temperature fault may be detected by an additional temperature sensing element integrated in the first vibration sensor 5. Any of speed fault, misalignment, bearing fault, drive-end (DE) bearing fault, non-drive-end (NDE) bearing fault, impeller fault, cavitation, and water hammer may have a specific vibration characteristic that may be analyzed by the evaluation module 9 to distinguish between the different types of internal faults. Dry-running may be detected by an ultrasonic sensor element integrated in the first vibration sensor 5.
The second signals from the second vibration sensor 7 are used by the evaluation module to validate or reject a discrimination among types of internal faults that the evaluation module 9 has based on the first signals alone. Based on the validated discrimination among internal fault types, the evaluation module 9 may trigger an information broadcast and/or an alarm, e.g. visual, haptic and/or audible, on a stationary or mobile computer device 37 of an operator. Thus, the confidence in the discrimination can be increased and incorrect alarms prevented by comparing the first signals and the second signals.
In case of an internal fault originating from the pump 3, e.g. misalignment, bearing fault, drive-end (DE) bearing fault, non-drive-end (NDE) bearing fault, impeller fault or cavitation, the first vibration sensor 5 at the pumphead 11 is expected to detect characteristic vibrations earlier than the second vibration sensor 7 at the pump inlet 13. The Euclidian vector direction, i.e. the sign, of the determined time delay may thus be used to distinguish between an internal fault and an external fault. The evaluation module 9 analyses the first signals and identifies one of a subset N of n types of internal faults originating inside the pump, where 1≤n≤k and (n, k E N). A comparison with the second signals is then used to validate or reject such an identification in order to increase the confidence in the identification of an internal fault type based on the first signals.
Where, in the foregoing description, integers or elements are mentioned which have known, obvious or foreseeable equivalents, then such equivalents are herein incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present disclosure, which should be construed so as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the disclosure that are described as optional, preferable, advantageous, convenient or the like are optional and do not limit the scope of the independent claims.
The above embodiments are to be understood as illustrative examples of the disclosure. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. While at least one exemplary embodiment has been shown and described, it should be understood that other modifications, substitutions and alternatives are apparent to one of ordinary skill in the art and may be changed without departing from the scope of the subject matter described herein, and this application is intended to cover any adaptations or variations of the specific embodiments discussed herein.
In addition, “comprising” does not exclude other elements or steps, and “a” or “one” does not exclude a plural number. Furthermore, characteristics or steps which have been described with reference to one of the above exemplary embodiments may also be used in combination with other characteristics or steps of other exemplary embodiments described above. Method steps may be applied in any order or in parallel or may constitute a part or a more detailed version of another method step. It should be understood that there should be embodied within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of the contribution to the art. Such modifications, substitutions and alternatives can be made without departing from the spirit and scope of the disclosure, which should be determined from the appended claims and their legal equivalents.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
Munk, Flemming, Nygaard, Michael Helbo, Kjeldsen, Søren
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